Ford FUSION Ford FUSION HYBRID 2010-2013 Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Fusion Model Variant: Fusion Hybrid Production Years Covered: 2010, 2011, 2012, 2013 Codes Engine Codes: Duratec 2.5L (I4), Duratec 3.0L (V6), Duratec 3.5L (V6), Duratec 2.5L Hybrid Transmission Codes: Manual Transmission, Aisin AW21 (Automatic), 6F35 (Automatic), E-CVT (Hybrid) 👋 Introduction Market Position Market Position: The Ford Fusion, particularly the Hybrid variant, was positioned as a stylish, fuel-efficient mid-size sedan, competing in a segment with strong contenders from Japanese and domestic manufacturers. The Hybrid model aimed at environmentally conscious buyers and those seeking lower running costs. Competitive Analysis Competitive Analysis: Competitors included the Toyota Camry Hybrid, Honda Accord Hybrid, Chevrolet Malibu Hybrid, and Hyundai Sonata Hybrid. The Fusion Hybrid differentiated itself with its sleek European-inspired styling and Ford's SYNC infotainment system. Key Features Key Features: The availability of multiple engine options, including a fuel-efficient hybrid powertrain, a spacious interior, advanced safety features, and a comfortable ride made the Fusion a popular choice. Manual Value Proposition Manual Value Proposition: This manual provides professional-grade repair and maintenance information, mirroring what certified Ford technicians use, enabling owners to perform extensive work, save on dealership costs, and ensure their vehicle's longevity and optimal performance. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive repair, maintenance, and servicing for Ford Fusion and Fusion Hybrid models. Page Count Page Count: 6700+ pages Manual Type Manual Type: Workshop Service Repair Manual & Owner's Manual Language Language: English Format Format: PDF (Download) 📖 Manual Coverage Systems Covered Engine Systems: Cooling, Fuel Charging & Control, Accessory Drive, Starting, Ignition, Emission Control, Intake Air, Exhaust, EVAP, Engine Control, Fuel System, Acceleration System Hybrid Systems: Hybrid System, Charging System, Battery, Mounting & Cables Transmission Systems: Manual Transmission, Automatic Transmission (Aisin AW21, 6F35), Continuously Variable Transmission (E-CVT), Clutch System, Transfer Case System (if applicable to models covered) Suspension And Steering: Suspension System, Wheels & Tires, Driveline & Driveshaft, Axle & Differentials, Steering & Power Steering, Steering Column & Switches Braking Systems: Brake System, Parking Brakes, Hydraulic Brake, Power Brake System, Anti-lock Brakes (ABS) Body And Interior Body Systems: Body Panels System, Body Repair, Body Mounting System, Roof Panel, Glass & Frame Interior And Comfort Interior Systems: Interior & Exterior, Mirror & Seat, Wiper & Washer, Instrument Panel, Lock & Entry System, Safety Belt System, Restraint System (Airbags) Electrical And Electronics Electrical Systems: Instrument Cluster, Climate Control System, Horn & Parking Aid, Entertainment System, Lighting System, Communication Network, Anti-Theft System, Remote Convenience, Cruise Control System, Multifunction Electronics Procedures Included Maintenance Procedures: Periodic Maintenance, Fluid Checks & Changes, Filter Replacements, Belt Inspection & Replacement Repair Procedures: Detailed step-by-step repair instructions for all covered systems, including engine rebuilds, transmission overhauls, brake component replacement, electrical diagnostics, and body panel repair. Diagnostic Procedures: Troubleshooting guides, fault code interpretation, diagnostic routines for various systems. Technical Depth Technical Depth: In-depth, technician-level information, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic maintenance to complex diagnostic and repair procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, fully printable for selected pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Content Features Visual Aids: Includes detailed exploded views, pictures, and diagrams. Searchability: Likely contains searchable text within the PDF for efficient information retrieval. ⚙️ Engine Specifications Primary Engine 2.5L Duratec I4: Displacement: 2.5 Liters (2500cc), Configuration: Inline 4-cylinder, Valve Train: DOHC, Fuel Delivery: Electronic Fuel Injection. Horsepower and torque figures vary by year, but typically around 175-179 hp and 170-172 lb-ft. 3.0L Duratec V6: Displacement: 3.0 Liters (3000cc), Configuration: V6, Valve Train: DOHC. Horsepower and torque figures typically around 240-245 hp and 222-225 lb-ft. 3.5L Duratec V6: Displacement: 3.5 Liters (3500cc), Configuration: V6, Valve Train: DOHC. Horsepower and torque figures typically around 263-273 hp and 249-250 lb-ft. 2.5L Duratec Hybrid: Combined System Power: Approximately 191 hp (engine + electric motor). Atkinson Cycle operation for enhanced efficiency. Integrated electric motor and Power Split Device (PSD). Performance Fuel Efficiency Hybrid: EPA estimated MPG figures typically in the range of 41 City / 36 Highway for the Fusion Hybrid (exact figures vary by model year and testing procedures). Fuel System Fuel Type: Unleaded Gasoline (87 octane recommended, higher may be specified for V6 models). Fluid Specifications Engine Oil 2.5L I4: SAE 5W-20, API SN or equivalent. Capacity: Approx. 5.4 US quarts (5.1 L) with filter change. Refer to specific year for exact specification. Engine Oil 3.0L V6: SAE 5W-20, API SN or equivalent. Capacity: Approx. 6.0 US quarts (5.7 L) with filter change. Refer to specific year for exact specification. Engine Oil 3.5L V6: SAE 5W-20, API SN or equivalent. Capacity: Approx. 6.0 US quarts (5.7 L) with filter change. Refer to specific year for exact specification. Engine Coolant: Ford Premium Engine Coolant (Gold Color), Motorcraft® Yellow Prediluted (10...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Fusion

Model Variant:

Fusion Hybrid

Production Years Covered:

2010, 2011, 2012, 2013

Codes

Engine Codes:

Duratec 2.5L (I4), Duratec 3.0L (V6), Duratec 3.5L (V6), Duratec 2.5L Hybrid

Transmission Codes:

Manual Transmission, Aisin AW21 (Automatic), 6F35 (Automatic), E-CVT (Hybrid)

👋 Introduction

Market Position

Market Position:

The Ford Fusion, particularly the Hybrid variant, was positioned as a stylish, fuel-efficient mid-size sedan, competing in a segment with strong contenders from Japanese and domestic manufacturers. The Hybrid model aimed at environmentally conscious buyers and those seeking lower running costs.

Competitive Analysis

Competitive Analysis:

Competitors included the Toyota Camry Hybrid, Honda Accord Hybrid, Chevrolet Malibu Hybrid, and Hyundai Sonata Hybrid. The Fusion Hybrid differentiated itself with its sleek European-inspired styling and Ford's SYNC infotainment system.

Key Features

Key Features:

The availability of multiple engine options, including a fuel-efficient hybrid powertrain, a spacious interior, advanced safety features, and a comfortable ride made the Fusion a popular choice.

Manual Value Proposition

Manual Value Proposition:

This manual provides professional-grade repair and maintenance information, mirroring what certified Ford technicians use, enabling owners to perform extensive work, save on dealership costs, and ensure their vehicle's longevity and optimal performance.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive repair, maintenance, and servicing for Ford Fusion and Fusion Hybrid models.

Page Count

Page Count:

6700+ pages

Manual Type

Manual Type:

Workshop Service Repair Manual & Owner's Manual

Language

Language:

English

Format

Format:

PDF (Download)

📖 Manual Coverage

Systems Covered

Engine Systems:

Cooling, Fuel Charging & Control, Accessory Drive, Starting, Ignition, Emission Control, Intake Air, Exhaust, EVAP, Engine Control, Fuel System, Acceleration System

Hybrid Systems:

Hybrid System, Charging System, Battery, Mounting & Cables

Transmission Systems:

Manual Transmission, Automatic Transmission (Aisin AW21, 6F35), Continuously Variable Transmission (E-CVT), Clutch System, Transfer Case System (if applicable to models covered)

Suspension And Steering:

Suspension System, Wheels & Tires, Driveline & Driveshaft, Axle & Differentials, Steering & Power Steering, Steering Column & Switches

Braking Systems:

Brake System, Parking Brakes, Hydraulic Brake, Power Brake System, Anti-lock Brakes (ABS)

Body And Interior

Body Systems:

Body Panels System, Body Repair, Body Mounting System, Roof Panel, Glass & Frame

Interior And Comfort

Interior Systems:

Interior & Exterior, Mirror & Seat, Wiper & Washer, Instrument Panel, Lock & Entry System, Safety Belt System, Restraint System (Airbags)

Electrical And Electronics

Electrical Systems:

Instrument Cluster, Climate Control System, Horn & Parking Aid, Entertainment System, Lighting System, Communication Network, Anti-Theft System, Remote Convenience, Cruise Control System, Multifunction Electronics

Procedures Included

Maintenance Procedures:

Periodic Maintenance, Fluid Checks & Changes, Filter Replacements, Belt Inspection & Replacement

Repair Procedures:

Detailed step-by-step repair instructions for all covered systems, including engine rebuilds, transmission overhauls, brake component replacement, electrical diagnostics, and body panel repair.

Diagnostic Procedures:

Troubleshooting guides, fault code interpretation, diagnostic routines for various systems.

Technical Depth

Technical Depth:

In-depth, technician-level information, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic maintenance to complex diagnostic and repair procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, fully printable for selected pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Content Features

Visual Aids:

Includes detailed exploded views, pictures, and diagrams.

Searchability:

Likely contains searchable text within the PDF for efficient information retrieval.

⚙️ Engine Specifications

Primary Engine

2.5L Duratec I4:

Displacement: 2.5 Liters (2500cc), Configuration: Inline 4-cylinder, Valve Train: DOHC, Fuel Delivery: Electronic Fuel Injection. Horsepower and torque figures vary by year, but typically around 175-179 hp and 170-172 lb-ft.

3.0L Duratec V6:

Displacement: 3.0 Liters (3000cc), Configuration: V6, Valve Train: DOHC. Horsepower and torque figures typically around 240-245 hp and 222-225 lb-ft.

3.5L Duratec V6:

Displacement: 3.5 Liters (3500cc), Configuration: V6, Valve Train: DOHC. Horsepower and torque figures typically around 263-273 hp and 249-250 lb-ft.

2.5L Duratec Hybrid:

Combined System Power: Approximately 191 hp (engine + electric motor). Atkinson Cycle operation for enhanced efficiency. Integrated electric motor and Power Split Device (PSD).

Performance

Fuel Efficiency Hybrid:

EPA estimated MPG figures typically in the range of 41 City / 36 Highway for the Fusion Hybrid (exact figures vary by model year and testing procedures).

Fuel System

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher may be specified for V6 models).

Fluid Specifications

Engine Oil 2.5L I4:

SAE 5W-20, API SN or equivalent. Capacity: Approx. 5.4 US quarts (5.1 L) with filter change. Refer to specific year for exact specification.

Engine Oil 3.0L V6:

SAE 5W-20, API SN or equivalent. Capacity: Approx. 6.0 US quarts (5.7 L) with filter change. Refer to specific year for exact specification.

Engine Oil 3.5L V6:

SAE 5W-20, API SN or equivalent. Capacity: Approx. 6.0 US quarts (5.7 L) with filter change. Refer to specific year for exact specification.

Engine Coolant:

Ford Premium Engine Coolant (Gold Color), Motorcraft® Yellow Prediluted (10 Year/150,000 Mile). Mixture: 50/50 ethylene glycol and deionized water. Capacity varies by engine, typically 8-10 US quarts (7.5-9.5 L).

🔧 Transmission

Standard

Manual Transmission:

Available on some non-hybrid models. Typically a 5-speed or 6-speed manual gearbox. Transmission fluid specification: Manual Transmission Fluid, W.K.T. 6264-D or equivalent. Capacity: Varies, typically 2.0-2.5 US quarts (1.9-2.4 L).

Optional

Automatic Transmission Aisin Aw21:

6-speed automatic transmission. Transmission fluid specification: MERCON LV Automatic Transmission Fluid. Capacity: Varies, approx. 7-9 US quarts (6.6-8.5 L) for refill.

Automatic Transmission 6F35:

6-speed automatic transmission. Transmission fluid specification: MERCON LV Automatic Transmission Fluid. Capacity: Varies, approx. 7-9 US quarts (6.6-8.5 L) for refill.

Hybrid Transmission E Cvt:

Electronically Controlled Continuously Variable Transmission (eCVT) coupled with the electric motor and gasoline engine. Uses a Power Split Device (PSD). Specific fluid requirements are critical and often proprietary; consult manual for details.

Features

Transmission Features:

Sport mode, manual shifting capability (on select automatics), and efficient power delivery designed to optimize fuel economy.

📐 Dimensions

Exterior

Length:

Approximately 190.6 inches (4841 mm).

Width:

Approximately 72.9 inches (1852 mm).

Height:

Approximately 58.1 inches (1476 mm).

Wheelbase:

Approximately 107.4 inches (2728 mm).

Interior

Front Headroom:

Approx. 38.7 inches (983 mm).

Rear Headroom:

Approx. 37.8 inches (960 mm).

Front Legroom:

Approx. 42.3 inches (1074 mm).

Rear Legroom:

Approx. 37.1 inches (942 mm).

Cargo

Cargo Volume Sedan:

Approximately 16.5 cubic feet (467 L).

Cargo Volume Hybrid:

Approximately 12.7 cubic feet (360 L) due to battery pack placement.

Weights

Curb Weight Base:

Approx. 3200-3300 lbs (1450-1500 kg) for base models.

Curb Weight Hybrid:

Approx. 3600-3700 lbs (1630-1680 kg) due to hybrid components.

🛡️ Safety Features

Ratings

NHTSA Overall Rating:

Generally received 4-star or 5-star ratings from the NHTSA for front, side, and rollover crash tests during its production run. Specific ratings vary by year and test.

IIHS Ratings:

Often achieved 'Good' ratings in IIHS crashworthiness tests for front, side, and rear impact. Specific model year and equipment dependent.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Stability Control (ESC) with Traction Control, Tire Pressure Monitoring System (TPMS).

Passive Features

Passive Safety Features:

Front airbags (driver and passenger), front side-impact airbags, side curtain airbags for front and rear occupants. Seatbelt pretensioners, LATCH child seat anchors.

💡 Technology Features

Infotainment

Infotainment System:

Ford SYNC infotainment system with voice recognition, Bluetooth connectivity, USB ports, and available navigation. Premium Sony audio systems were also optional.

Driver Assistance

Driver Assistance Features:

Available features included rear parking sensors, rearview camera, blind-spot monitoring, and adaptive cruise control (depending on trim level and options).

Connectivity

Connectivity Options:

SYNC system provided hands-free calling, music streaming, and text messaging capabilities. Later models offered FordAppLink for access to specific smartphone applications.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, depending on driving conditions and oil type used (synthetic blends or full synthetic recommended). Refer to Owner's Manual for exact interval.

Tire Rotation Interval:

Every 5,000 to 7,500 miles (8,000 to 12,000 km) to ensure even wear.

Transmission Fluid Change:

For automatics (AW21, 6F35), often recommended at 60,000 to 100,000 miles (96,000 to 160,000 km) or under severe driving conditions. For manual and eCVT, consult the manual as intervals can differ significantly.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 Motorcraft® High-Temperature Brake Fluid. Capacity: Varies, typically 1-2 US quarts (0.9-1.9 L) for a full flush.

Power Steering Fluid:

Refer to manual for specific fluid type, likely a high-quality power steering fluid. Capacity varies.

Known Issues

Common Issues:

Potential issues can include throttle body problems, occasional transmission shifting harshness, water pump leaks (especially on V6 engines), and HVAC system malfunctions. Hybrid specific issues might involve the hybrid battery or inverter, though these are generally robust.

Filter Part Numbers

Oil Filter 2.5L I4:

Motorcraft: FL-500S, WIX: 57356, Fram: PH7317 (Verify compatibility for exact year).

Air Filter Engine:

Motorcraft: FA-1854 (Verify compatibility for exact year and engine).

📚 Vehicle History

Brand Heritage

Brand Heritage:

Ford, an American automotive giant, has a long history of producing reliable and popular vehicles, including a strong presence in the truck market with the F-Series and a diverse range of sedans and SUVs.

Model Evolution

Fusion Generation 1 Evolution:

The first generation Ford Fusion (2006-2012) introduced a distinct European design influence, shared a platform with the Mazda 6, and offered a range of four- and six-cylinder engines. The Fusion Hybrid was introduced in 2010 as part of this generation's mid-cycle refresh.

Fusion Generation 2 Transition:

While this manual covers up to 2013, the second generation Fusion (starting model year 2013) represented a significant redesign with updated styling, powertrains, and technology, including a new hybrid variant.

Production

Production Location:

Ford Fusion models, including the Hybrid, were primarily assembled at the Ford Flat Rock Assembly Plant in Flat Rock, Michigan, USA.

🏆 Awards & Recognition

Recognitions

Hybrid Powertrain Recognition:

The Fusion Hybrid often received praise for its fuel efficiency and smooth operation, contributing to Ford's reputation for developing viable hybrid technology. Awards like Green Car of the Year nominations were common for competitive hybrids.